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| Mistake Proofing Systems: 7 Keys to Successful ImplementationNovember 1, 2004 Mistake
proofing is a powerful tool for creating more stable processes by reducing
defects. Processes with high defect
rates are very problematic for the lean producer: such processes are not
conducive to a lean value stream because they require overproduction to ensure
that demand is met. This article
will teach you how to implement an effective mistake proofing system. This article talks about seven keys
to implementing an effective mistake proofing system: Key
#1: Create a team and always include those
people that work on process in question. Organizations
still have the tendency to turn to “technical experts” working in isolation
to implement poka-yoke systems. Involving
operators in a team setting will dramatically increase the likelihood of
success. A kaizen blitz event is
one very effective team activity for implementing mistake proofing. Key
#2: Use Value Stream Mapping to determine
where process stability must improve. (If
you are not familiar with value stream mapping, go back and read our series of
articles on the subject.) This
will allow you to focus on areas that will impact continuous flow. Key #3: Use process mapping within the area selected. If you are implementing mistake proofing as a part of a kaizen blitz event, then this step should be done as a matter of course. However, if you are not using this methodology, you still need to map the current state process in detail. This will clearly identify each process step. Key
#4: Use a simple problem solving
methodology like a fishbone diagram to determine root causes of problems within
the process. This will identify
those specific steps in the process that need mistake proofing. Key
#5: Use the simplest technology that will
work when implementing a poka-yoke. Many
times, low-tech solutions like guide pins and limit switches will work
effectively. However, there are
times when more complicated systems are necessary. Key
#6: Use control systems instead of warning
systems wherever practical because control systems are not operator-dependent. (Control systems stop equipment when an irregularity happens,
while a warning system signals the operator to take action). Key
#7: Have a standard form for every
“Poka-Yoke” that indicates the: ·
Problem being addressed ·
Emergency alarm that will sound ·
Action to be taken in an
emergency ·
Method and frequency of
confirming it is operating correctly ·
Method to perform a quality
check in case of breakdown Mistake
proofing systems are critical to the success of a lean organization simply
because process stability is so critical. Using
the above seven keys will improve the likelihood of implementing a successful
mistake proofing program. Click here to subscribe to our free e-newsletter Learning to Lean and receive three articles like this one each month. About the Author Darren Dolcemascolo is an internationally recognized lecturer, author, and consultant. As Sr. Partner and co-founder of EMS Consulting Group, he specializes in productivity and quality improvement through lean manufacturing. Mr. Dolcemascolo has written the book Improving the Extended Value Stream: Lean for the Entire Supply Chain, published by Productivity Press in 2006. He has also been published in several manufacturing publications and has spoken at such venues as the Lean Management Solutions Conference, Outsourcing World Summit, Biophex, APICS, and ASQ. He has a BS in Industrial Engineering from Columbia University and an MBA with Graduate Honors from San Diego State University. | |||||||||||||||||
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